Technology focused on fertilizer production

Compaction is the process of compressing fine-grained solids between two counter-rotating smooth or profiled rollers, for example in a Köppern roller press. The resulting band of material, known as flake, is an intermediate product from which the final granulate is produced using crushing and screening processes.

While the technology is also found in many chemical industry applications, the compaction process traditionally is mainly used to produce either single-component (KCI) or multi-component (NPK) fertilizers.

Besides single-component fertilizers containing only N (nitrogen) for example, mixed fertilizers are also available. These each contain two or more of the nutrients N, P (phosphor) and K (potassium). 

Disadvantages arising during storage, transportation and handling of fertilizers, such as segregation, uncontrolled agglomeration, unsatisfactory flow characteristics, or losses during application due to dusting or run-off, are largely avoided by using granulated fertilizers. 

Several fertilizer granulation techniques have been developed which are based on either wet agglomeration or on dry (press) agglomeration without binding agents, with subsequent crushing and sizing into the final granular size. However, comparative tests with wet and dry granulation have shown that even a most unfavorable dry granulating system is distinctly superior to the best wet granulating system, especially regarding the energy consumed by the heat treatment required for drying during the wet granulation process.

Köppern not only manufactures the roller presses but also provides complete fertilizer production plants. Additionally, our range of services includes compaction tests, process layout, basic engineering and installation and start-up support.